Fiber Products, Prepregs, Composites and Method of Producing Same

ABSTRACT

The present disclosure includes a method to make 3D fibers products, prepregs and composites, by using fastening components cross plies, strands, and yarns.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation application of, and claims thebenefit of U.S. Non-Provisional application Ser. No. 11/925,752, filedon Oct. 27, 2007, now allowed, which is incorporated by reference in itsentirety. This application also claims the benefit of U.S. ProvisionalApplication No. 60/854,632, filed on Oct. 27, 2006, to which U.S.Non-Provisional application Ser. No. 11/925,752 claims priority to.

FIELD OF THE INVENTION

The present invention relates to 3 dimension (3D) fibers, 3D fabrics, 3Dpreforms, 3D prepregs and 3D composites and methods to make them usingtextile industry technologies, hook and loop technologies, plasticindustry technologies and nano-fiber technologies, with the objects toincrease their mechanical strength, interlaminate strength, fatiguedurability and impact resistance, and their manufacturability.

BACKGROUND OF THE INVENTION

Fiber composite materials have been used in the industry over the pastthree decades. However, their utilization in the primary load-bearingstructures has been limited by its high sensitivity to out-of-planefailures resulting from the low interlaminar fracture toughness. Methodto alleviate these problems is to improve delamination resistance in thethickness direction by stitching, 3D weaving, 3D knitting, 3D braid.Those 3D technologies need complicated machines and manufacturingprocesses. So layer-by-layer lay-up and filament wrapping are stillmajor processes in composite industry.

The present invention provides methods to make 3D composites incompatible to 2D manufacturing process.

SUMMARY OF THE INVENTION

The present invention is to provide methods to make 3 dimension (3D)fibers, 3D fabrics, 3D preforms, 3D prepregs and 3D composites, by usinghook and loop (VELCRO), hook and hook, zipper heads, fish hook, and/orarrow head and mushroom head fastening components, across layers,strands and yarns. One sheet of fibers has one or multiple kinds of theabove said fastening components on one side and their fasteningcounterparts on the other side. Laying up the sheets with said fasteningcomponents on its two side as regular 2D sheets can obtain a 3D preform.The sheets can be torn apart if re-lay-up is needed. A fiber or yarn canhave the said fastening components around 360 degree on its surface.Laying up the fibers and yarns with said fastening components togetheror intercrossing each other can get a 3D preform. In those preforms, twoparts of the said fastening components can lock each other if they meetand engage. A 3D composite structure can be made by using the 3D preformin resin infusing, resin film infusing, resin protrusion or RTM. Thefastening components can be arranged in pattern arrays to increasestrength against specified loads.

One weaved or non-weaved sheet of fiber with the said fasteners on bothsides or a yarn is first impregnated with resin. Then let theimpregnated fiber sheet or the yarn dry. A piece of prepreg with thesaid fasteners or a yarn prepreg is then made. Finally, lay and pressthe prepreg sheets together to any desired thickness. The fasteningcomponent can lock each other if they meet and engage. In a curingprocess, the resin can melt and the fastening components can furtherinterlock each other. So a 3D composite structure is made by the said 3Dprepregs. Wrapping the yarn prepreg can get a 3D composite too.

The fastening components of hook and loop (VELCRO), hook and hook,zipper heads, fish hook, arrow head and mushroom head can be made ontothe sheet fiber (weaved or non-weaved), strands and yarns by textileindustry technologies, such as weaving, knitting, warp knitting, braid,stitching, and hook and loop (VELCRO) technologies, and by non-weavingtechnologies, such as needle penetrating, air-blowing fasteners onfibers and air- or water-jet shooting fasteners on fibers. The fasteningcomponents can be bonded on, glued on, welded on, compressed on, orgrown on the fibers.

The two parts of fastening components can have acute angles to theirbase sheet or fibers. The acute angle can allow the two part fasteningcomponents to engage like sharp teeth to increase their locking. Thefastening components can be made from all kinds of suitable materialsincluding nano fibers, strands and filaments, nanotubes, nano forks, andnano arrows.

This 3D fiber technology can be used in rubber, building materials andplastic industries.

BRIEF DESCRIPTION OF THE FIGURES

FIG. 1 shows a view of an exemplary sheet of fibers with hook, loop andother fastening components on its both sides.

FIG. 2 shows a view of an exemplary composite made by the fiber sheetswith fastening components. Several of sheets make the preform andcomposite. The trans-layer fastening components make a 3D composite.

FIG. 3 shows a view of an exemplary 3D prepreg sheet with hook, loop andother fastening components on its both sides.

FIG. 4 shows a cross-section view of the 3D prepreg of FIG. 3.

FIG. 5 illustrates an exemplary process of using mold to control thehook, loop and fastening fibers shape, direction, and angle or usingchemical air to obtain the shape and angle and direction of thefastening fibers.

FIG. 6 shows a view of exemplary trans-layer hook and loop fibers.

FIG. 7 illustrates an exemplary process of using laser to cut loops toget hooks.

FIG. 8 illustrates an exemplary process of using laser and heat iron tomake hooks.

FIG. 9 shows variety of exemplary hooks. Several fibers are yarned andbonded together by glue to make the hooks stiffer.

FIG. 10 shows variety of exemplary loops.

FIG. 11 shows a transparent view of an exemplary block of composite madefrom 3D forks and branches.

FIGS. 12A-12F show exemplary filaments having hook and loops and otherfastening components.

FIG. 13 shows an exemplary pressure bottle made from filaments withfastening components.

FIG. 14 shows an exemplary vest made from the 3D composites.

FIG. 15 shows an exemplary helmet made from 3D composites.

FIGS. 16A-16C show an exemplary stem fiber having 3 dimension branchesand forks.

FIGS. 17A-17B show an exemplary networking of 3D branches and forks.

FIGS. 18A-18B show 3D branch, hook directions in an exemplary composite.

FIGS. 19A-19B show exemplary vertical trans-layer and interlayer fibershaving acute angles along their long direction. The acute angle verticalfibers can bite into each other and engage. This locking can havestronger strength against shear load and tear load.

FIG. 20 shows a view of an exemplary composite having acute hooks atdifferent directions.

FIG. 21. shows an exemplary view of acute angle hooks and loopsinterlocking between fiber layers.

FIG. 22 shows an exemplary view of the engagement of hooks and hooks,hooks and loops.

FIG. 23 shows an exemplary process of using a spiral screw cylinder tomake the hooks, loops and fibers in the curves of spiral spur gear.

FIG. 24 shows an exemplary process of using a needle to bring hook andloop fibers trans-layer.

FIG. 25 shows an exemplary process of using air blow, air jet, or waterjet to shoot hook and loop fibers trans-layer and stay on the layer.

FIG. 26 shows the loop on an exemplary woven towel.

FIG. 27 shows that small loops are formed on the surface of an exemplaryfabric by the use of complex yarns.

FIG. 28 shows an exemplary view of patterned knitted fabric loops.

FIG. 29 shows the other side of the fabric of FIG. 28. Cutting the loopscan get hooks.

FIG. 30 shows an exemplary view of compressing the hook and loop fabricon a net.

FIG. 31 shows an exemplary view of the hook and loop pattern made byembroidery.

FIG. 32 shows an exemplary view of loops on a bath towel.

FIG. 33 shows an exemplary view of a bath towel with loops.

FIG. 34 shows an exemplary process of cutting the fiber to get thehooks.

FIG. 35 shows an exemplary process of obtaining fibers and hooks bynapping a yarn.

FIG. 36 shows an exemplary view of hooks and loop connecting blankets inthe transverse direction.

FIG. 37 shows an exemplary view of fiber strands combined with finesimple yarns.

FIG. 38 shows an exemplary view of stitch and knit making the loops.

FIG. 39 shows an exemplary view of stitch and knit making the loops.

FIG. 40 shows an exemplary view of fastening components in belt areas onthe sheets.

FIG. 41 shows an exemplary view of fastening components in belt areas onthe sheets.

FIG. 42 shows an exemplary view of carbon nanotubes with varyingdiameters along length.

FIG. 43 shows an exemplary view of adhesive or coating materials holdinga bunch of fiber hooks together.

FIG. 44 shows an exemplary view of a group of fiber loops on a sheet.

FIG. 45 shows an exemplary process of using a flocking process and amodified flocking process to prepare vertical short fibers on fibersheet or other substance surface.

FIG. 46 shows an exemplary process of a flocking application by anelectrostatic method.

FIG. 47A shows an exemplary view of the fiber sheet net and adhesive netfilm with a designed pattern on them.

FIG. 47B shows an exemplary view of the fiber sheet net and adhesive netfilm with a designed pattern on them.

FIGS. 48A-48B show an exemplary view of the adhesive net films attachedto the two sides of fiber sheet.

FIG. 49 shows an exemplary view of the fiber sheets with flockedvertical fibers. Loops and hooks are stacked together.

FIG. 50 shows an exemplary process of flocking fibers on adhesive filmand transferring on fibers.

FIG. 51 shows an exemplary view of a net having hooks, loops andmushroom heads on its both sides.

FIG. 52 shows an exemplary process of using complex yarn technology tomake the yarns.

FIG. 53 shows an exemplary view of the yarn with varying width along itslength.

FIG. 54 shows an exemplary view of wider yarns making the tube andbottle curve area stronger.

FIG. 55 shows an exemplary view of the hook, loop, mushroom head andfastening components attached on yarns just like the barb on a barbedwire.

FIG. 56 shows an exemplary process of using stables to make 3D preformsand composites.

DETAILED DESCRIPTION

Referring to FIG. 1, a sheet 10 of fibers or film has hook 11, loop 12,anchor-like hook 13, fish hook 14, fork 17 and 21, big head 18,arrow-like hook 19 and group loop 20 fastening components on both sidesof the sheet. A hook can have multiple hooks 15 and 16 like a hookstring. The fastening components can form a pattern or an array on thesheet with specified directions. The fastening components can berandomly scattered or mixed on the sheet.

As shown in FIG. 2, several sheets 10 can be laid togetherlayer-by-layer to form a preform 30. The hook and loop, hook and hookand other fastening components can engage each other to providetrans-layer and interlayer reinforcements. The top and bottom sheet canhave fastening components on only one side of the sheets.

FIG. 3 shows that resin 35 infiltrates the fiber sheet 10 to form apiece of prepreg 33. FIG. 4 shows a cross-section view of prepreg 33.The hook and loop, and fastening components 37 and 38 can be above theresin and stand out of the sheet, or can stay right under the resinsurface. The fastening components can engage each other when the resinbecomes liquid during curing. The resin 35 can have a low step 36 wherefastening components are lower than the surrounding resin. The fasteningcomponents can be protected by the higher surrounding resin.

FIG. 5 illustrates an exemplary process of using mold and chemical airto obtain the hook, loop and fastening component shape, direction, angleand dimension.

FIG. 6 is a section view of trans-layer hook and loop fibers. They canbe made by textile industry technologies, such as weaving, knitting,warp knitting, braid, stitching, by hook and loop (VELCRO) technologies,and by non-weaving technologies such as needle penetrating, air-blowingfasteners on fibers, and air- or water-jet shooting fasteners on fibers.The fastening components can be bonded on, glued on, welded on,compressed on, and grown on the fibers.

FIG. 7 shows an exemplary process of using laser to cut the loops to gethooks. Knife also works to cut the fibers to get hooks.

FIG. 8 shows an exemplary process of using laser and heat iron to treatthe fibers and make the hooks and loops in a specified direction andangle.

Some embodiments of the hooks a1-a28 are illustrated in FIG. 9. Hook 40(a2-a4) can have several fibers bonded together by adhesive 41 to makethe hook much stiffer. Hook 42 can have several short fibers and severallong fiber bonding together. Those hook 11, anchor-like hook 13, fishhook 14, fork 17 and 21, big head 18, arrow like hook 19 and group loop20 fastening components are also shown in FIG. 1.

Some embodiments of the loops b1-b9 are illustrated in FIG. 10.

FIG. 11 shows that the rod/fiber 45 can have branches 46 coming out ofitself at any direction. Fiber 45 and branch 46 can be made of differentmaterials. The fibers 45 are aligned together and their branches 46 arecross-linked together. Therefore a 3D preform is made. The sheets can betorn apart if re-lay-up is needed. Infiltrating a 3D preform with resincan get a 3D composite.

FIG. 12 shows that yarns (a)-(f) can have hooks and loops and otherfastening components. They can be made by complex yarn technology, bybarbed wire entanglement technology, and by air blow technology. Airblow and jet or water jet can shoot the fastening components on theyarns. The yarns are then infiltrated by resin 35 to get yarn prepregs.

A bottle can be made by wrapping said yarns or yarn prepreg, as shown inFIG. 13. The yarn can vary its width 76 along its length. A wider yarnor belt 76 can make the curve area stronger. The fastening componentscan engage during wrapping. So a bottle is made with higher impactresistance 3D composite.

3D composites can be used to make vest and helmet to protect people, asshown in FIG. 14 and FIG. 15.

FIG. 16 shows that a rod, yarn, or fiber 50 can have branches 51 andforks 53 coming out from its stem and standing out to the space aroundthe stem in 3 dimensions. Part of the branch 51 can have curve 52 actingas a hook. The part 52 can be in the same material as branch 51 or inother material bonded to branch 51. The fork 53 on branch 51 issub-branches. The sub-branch 53, knot 54 and arrow-like tooth 55 onbranch 51 or even stem 50 can act as fastening components. Tooth 55 canhave a sharp face 56.

FIG. 17 shows that several fibers 50 can engage together by theirbranches 51 and the fastening components on their branches.

The acute angle 57 of branch to stem can help the engagement of branchesto increase the engagement chance and strength. The sub-branch 53 isshort enough for penetrating and long enough for acting as a hook. Anacute angle 57 of the sub-branch can help the penetrating. The acuteangle 58 of branch to the interlayer straight distance line 59 can alsobe important to the engagement.

FIG. 18 shows the fibers 50 in fiber sheets. When the fiber sheets arelaid up together, the branches 51 and their fastening components canengage and interlock together to form 3D preform, prepreg and composite.The branches can have back-to-back and face-to-face engagement due tothe acute angel 57 direction (branch direction), which helps to increasethe strength against sheer and tear load.

FIG. 19 is a section view showing fibers' face-to-face engagement offastening components. An acute angle fiber or branch faces another fiberor branch in acute angel.

FIG. 20 shows several fiber sheets laid up together. Some areas of thesheets can have the same direction of fastening components (branch,hook, loop), marked by arrow 60. A sheet with different direction offastening components can make the composite have good strength againstdifferent direction load.

A face-to-face lock is illustrated in FIG. 21, just like sharp teethbitten together. The fastening components with acute angles areimportant in controlling the fastening direction when the fiber sheetsare compressed.

FIG. 22 shows that hooks, loops and fibers can be made in the curves ofa spiral spur gear or a spiral screw cylinder. Those curves help thehooks and loops engagement.

FIG. 23 shows an exemplary process of using a spiral screw cylinder 62to make the hooks, loops and fibers in the curves of spiral spur gear63.

FIG. 24 shows an exemplary process of using needles 64 to bring hook andloop fibers trans-layer.

FIG. 25 shows an exemplary process of using air blow, air jet, or waterjet 65 to shoot hook and loop fibers trans-layer and staying on thelayer.

FIG. 26 shows the loops on a woven towel.

FIG. 27 shows small loops are formed on the surface of the fabric by theuse of complex yarns.

FIG. 28 shows patterned knitted fabric loops.

FIG. 29 shows other side of the fabric of FIG. 28. Cutting the loops canget hooks.

FIG. 30 shows compressing the hook and loop fabric on a net 66.

FIG. 31 shows the hook and loop pattern made by embroidery.

FIG. 32 shows loops on a bath towel. Terry cloth, used in towels androbes, is constructed with uncut loops of yarn on both sides of thesheet cloth. These loops are formed by holding the ground wrap yarnsunder tight tension and leaving the wrap yarns that form the pile in aslack state. The shed is made and picks are inserted. And this isrepeated for a specified number of picks, usually three, without anybeating in. After the picks have been placed, they are battened intoposition. This causes the slack wrap yarns to be pushed into loopsbetween the picks. While the typical terry cloth has loops on bothsides, it is possible to make fabrics by this method with loops on onlyone side. Hook yarns are recommended to be stiff. And loop yarns aresofter.

FIG. 33 shows a bath towel with loops.

FIG. 34 shows cutting the fiber to get the hooks.

FIG. 35 shows obtaining the fibers and hooks by napping a yarn 67.

FIG. 36 shows hooks 11 and loop 12 connecting blankets in the transversedirection.

FIG. 37 shows fiber strands are combined with fine simple yarns.

FIG. 38 and FIG. 39 show that stitch and knit make the loops.

FIG. 40 and FIG. 41 show the fastening components can be in belt areason the sheets. So the two sheets can easily engage in the belt areas.

FIG. 42 illustrates that the carbon nanotubes can have big head 23 atits ends. The big heads are the end areas having bigger diameters. Thebig diameter tube area can be single layer tube and/or multiple tubelayers. The big diameter area can be located along the tube like achain. Two big diameter areas 24 can hold the tube on a fabric or athread. The bigger diameter areas can have one end with sharp edge 25acting as hook and another end with smooth cure 26 acting as a bullethead for penetrating fibers and loops.

FIG. 43 shows adhesive or coating materials 27 holding a bunch of fiberhooks 22 together to make the hook stronger and stiffer. Those stifferhooks are easier to penetrate fiber loops and bundles to lock with them.

FIG. 44 shows a group of fiber loops 20 on a sheet 10.

FIG. 45 shows an exemplary process of using a flocking process and amodified flocking process to prepare vertical short fibers on fibersheet 10 or other substrate surface 18. The flocking process involvesapplying short fibers 11, fiber bundles 22 and bonded fibers 27 directlyon to a substrate that has been previously coated with an adhesive. Theprocess uses mechanical or electrical equipment that mechanically erector electrically charges the flock short fibers causing them to stand up.The short fibers are then propelled and anchored into the adhesive atnear right and right angles to the substrate. The flocking process canbe accomplished by one of the four methods: electrostatic, beaterbar/gravity, spraying, and transfers. Flocking material can also bespayed using an air compressor, reservoir and spay gun similar to theone spaying paint. Flocking can also be applied by printing an adhesiveon to a material, and then rapidly vibrating the substrate mechanically,while the flock fibers are dispensed over the surface.

The vibration promotes the density of fibers and causes the flockingfibers to adhere to the adhesive and pack into a layer. This process isa beater bar or gravity flocking system.

FIG. 46 shows a flocking application by the electrostatic method. Thefiber sheet 10 goes between positive electrode grid 73 and groundelectrode 72 to let flocking short fibers penetrate fiber sheet andadhesive film and stay on them.

In FIGS. 47A and 47B, the fiber sheet 10 is attached to an adhesive netfilm 70 underneath. The adhesive standoff 71 on the net film attach tothe fiber sheet 10 and make a gap between the adhesive net film andfiber sheet. The fiber sheet is loose enough to let the flocking shortfibers penetrate fiber sheet to reach, penetrate and stay on theadhesive net film below. FIG. 47A and FIG. 47B show the fiber sheet 10and net adhesive net film 70 with a designed pattern on them. So shortfibers with hooks and loopos can penetrate fiber sheet 10 and adhesivenet film 70 and stay on them at desired areas according to the patterns.

FIG. 48A and FIG. 48B show the adhesive net films 70 can be attached tothe two sides of fiber sheet 10. The adhesive film 70 has window 74 toallow short flocking fibers to penetrate fiber sheet 10 and stay atdesired areas.

FIG. 49 shows the fiber sheets with flocked vertical fibers, loops andhooks are stacked together. During curing process, the adhesive melt andthe hooks and loops link together.

A much easier way to add flocking to materials is to apply standardflocking transfers. Basically the flocking process is virtually the sameas the one for a screen printing with only a few differences. FIG. 50shows the short fibers are flocked on adhesive film 70 and then transferonto the fiber sheet 10.

If the short fibers are dielectric, a chemical treatment is needed toenable the fibers to accept an electrical charge. A certain amount ofconductivity must be present for electrostatic flocking process tooccur.

FIG. 50 shows flocking fibers on adhesive film and transferring them onfiber sheets.

FIG. 51 shows a net 75 has hooks, loops and mushroom heads on its bothsides. The hooks, loops and mushroom heads can go through fiber sheet 10to link with next net 75 when the nets 75 and fiber sheets stacktogether.

FIG. 52 shows using complex yarn technology to make the yarns. The hooksor mushroom heads can have multiple stands 22 and be bonded withmaterial 27 to make them stronger and harder.

FIG. 53 shows a yarn can vary its width 76 along its length. So thewider yarn or even belt 76 makes the tube and bottle curve areastronger, as shown in FIG. 54.

The hooks, loops, mushroom head and fastening components can attach onyarns just like the barb on a barbed wire, as shown in FIG. 55.

Stables can also be used to make 3D preforms and composites, as shown inFIG. 56. Threads 22 can become a stable with adhesive 27. Using aregular stable machine and a flocking process can let the thread stablespenetrate fiber sheets to make 3D preforms and composites.

1. A 3-dimension (3D) multi-layer composite, comprising: a first fibersheet with a first plurality of fastening components on both surfaces ofthe first fiber sheet, the first plurality of fastening componentspenetrating through the first fiber sheet and extending outwardly fromboth surfaces of the first fiber sheet; and a second fiber sheet with asecond plurality of fastening components on both surfaces of the secondfiber sheet, the second plurality of fastening components penetratingthrough the second fiber sheet and extending outwardly from bothsurfaces of the second fiber sheet, wherein the first plurality offastening components mechanically engage with the second plurality offastening components, wherein the first and second plurality offastening components are put on the first and second fiber sheets byflocking; wherein at least one of the first fiber sheet and the secondfiber sheet has an adhesive net film on a top, and/or a bottom side ofsaid at least one of the first fiber sheet and the second fiber sheet,and the fastening components of the first or second fiber sheet havingthe adhesive net film extend in or through the adhesive net film;wherein the first and second fiber sheets have sufficiently largeopenings for allowing penetration of the fastening components throughsaid fiber sheets.